Instruction Sheet

CERTI-CRIMP* 408-1559
Hand Crimping Tools 11 JAN 16 Rev U

PROPER USE GUIDELINES

Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low
volume applications. A wide selection of powered application equipment for extended-use, production operations is available.

ORIGINAL INSTRUCTIONS
Handles

Label (Color Coded for PIDG* Hand Crimping Tool

and PLASTI-GRIP* Products) Part Numbers
46121
Wire Size Range 47304
Stamped Here 47386
47386-5
Ratchet
Locator 47387
47907-1
Label (Color Coded 48518-2
for Sealed Splices) 68343-1
69151-1
Insulation Crimp Adjustment Pins 69454
Jaws (Shown in Position 3) 169485

Figure 1

1. INTRODUCTION
CERTI-CRIMP hand crimping tools listed in Figure 1 are used to crimp the products onto the wire listed in
Figure 2.
NOTE
Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures and illustrations are for reference only
and are not drawn to scale.
Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY.

2. DESCRIPTION (Figure 1)
The handles and label (if applicable) of each tool are color-coded to match the color coding of the product to be
crimped. The tools may show more than one color code.
COPPER WIRE
PRODUCT
TYPE SIZE RANGE (AWG)
PIDG Terminals and Splices Solid or Stranded 30-14
PIDG Radiation Resistant Terminals and Splices Stranded 27-14
PLASTI-GRIP Butt Splices Solid or Stranded 26-22
PIDG Insulation Restricting Nylon Terminals Stranded 26-14
PIDG FASTON* Receptacles 641321-1 (.187 Series) and 641324-1 (.110 Series) Stranded 26-24
PLASTI-GRIP Terminals Solid or Stranded 22-14
Spare Wire Cap Stranded 22-14
Figure 2
These tools are members of the CERTI-CRIMP hand crimping tool family. The ratchet ensures full crimping of
the product. Once engaged, the ratchet will not release until the handles have been FULLY closed.
CAUTION
The crimping jaws bottom before the ratchet releases. This design feature ensures maximum tensile performance of the crimp.
DO NOT re-adjust the ratchet.

© 2016 TE Connectivity family of companies PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
All Rights Reserved For latest revision and Regional Customer Service,
1 of 10
*Trademark visit our website at www.te.com.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
 408-1559

3. CRIMPING PROCEDURE
Refer to Figure 3 to ensure that the correct tool and product combination is being used. Figure 3 also lists the
number of dots (or dots and rib) that appear embossed on a crimped product when it is crimped using the
correct tooling.

3.1. PIDG and PLASTI-GRIP Terminal and Splice and PIDG FASTON Receptacle
1. Strip the wire to the dimension provided in Figure 3 being careful to avoid nicking or cutting the
conductor(s).
CAUTION
DO NOT use wire with nicked or missing conductor(s).
2. Open the tool jaws by closing the tool handles until the ratchet releases, then allow the handles to
open fully.
TOOL PRODUCT WIRE

PART COLOR DOT SIZE RANGE INSUL DIA STRIP LENGTH

DESCRIPTION INSUL COLOR
NO. CODE CODE (AWG) RANGE TERMINAL SPLICE

46121 Red and PIDG Terminals and Splices

1 4.0-4.8 4.4-5.2
169485 Yellow PLASTI-GRIP Butt Splices Yellow 26-22 ---
[5/32-3/16] [11/64-13/64]
47304● Yellow --- PIDG Terminals
PIDG Terminals and Splices Natural Translucent
Blue and 4.8-6.6 5.6-6.4
47907-1 2 PIDG Radiation Resistant Natural Translucent 24-20 ---
White [3/16-7/32] [7/32-1/4]
Terminals and Splices with White Stripe
PIDG Terminals
Yellow
MS 25036-143 through -147
47386 Red and 5.2-6.0
1 PIDG Radiation Resistant 26-24 --- ---
47386-5 Yellow Natural with Yellow [13/64-15/64]
Terminals
Stripe
MS 7928/4-143 through -147
PIDG Terminals and Splices
Red
47386 Red and PLASTI-GRIP Terminals 5.2-6.0 6.4-7.1
1 22-16 ---
47386-5 Yellow [13/64-15/64] [1/4-9/32]
PIDG Radiation Resistant Natural Translucent
Terminals and Splices with White Stripe
PIDG Terminals and Splices
Red
PLASTI-GRIP Terminals 5.2-6.0 6.4-7.1
69151-1● Red --- 22-16 ---
[13/64-15/64] [1/4-9/32]
PIDG Radiation Resistant Natural Translucent
Terminals and Splices with White Stripe
PIDG Terminals and Splices
Red
1 Dot PLASTI-GRIP Terminals 5.2-6.0 6.4-7.1
69454 Red 22-18 ---
1 Rib [13/64-15/64] [1/4-9/32]
PIDG Radiation Resistant Natural Translucent
Terminals and Splices with White Stripe
1.04-2.62
Blue 16-14
PIDG Terminals and Splices [.041-.103]
PLASTI-GRIP Terminals 20-16 0.41-1.65
Blue and Green 5.2-6.0 6.4-7.1
47387 2 HD [.016-.065]
Green [13/64-15/64] [1/4-9/32]
16-14
PIDG Radiation Resistant Natural Translucent
20-16 ---
Terminals and Splices with Blue Stripe
HD

●Use Tight Insulation Support for Wires with Thin Wall Insulation

Figure 3 (cont’d)

Rev U 2 of 10
 408-1559

TOOL PRODUCT WIRE

PART COLOR DOT SIZE RANGE INSUL DIA STRIP LENGTH

DESCRIPTION INSUL COLOR
NO. CODE CODE (AWG) RANGE TERMINAL SPLICE
Yellow with 3 0.66-1.40
46121 26
Red and PIDG Insulation Restricting Black Stripes [.026-.055] 4.8-5.6
169485 1 ---
Yellow Nylon Terminals Yellow with 3 0.79-1.40 [3/16-7/32]
47304● 24
Blue Stripes [.031-.055]
Yellow with 3 0.66-1.40
PIDG Insulation 26
47386 Red and Restricting Nylon Black Stripes [.026-.055] 6.4-7.1
1 ---
47386-5 Yellow Terminals Yellow with 3 0.79-1.40 [1/4-9/32]
MS 7928/1-1 through -10 24
Blue Stripes [.031-.055]

Red and Red with 3 0.97-1.40

22
Yellow Green Stripes [.038-.055]
47386
PIDG Insulation Restricting Red with 3 1.17-2.79 6.4-7.1
47386-5 Tool 1 20 ---
Nylon Terminals Red Stripes [.046-.110] [1/4-9/32]
69151-1● 69151-1
Mod F Red with 3 1.42-2.79
Red Only 18
White Stripes [.056-.110]
Blue and PIDG Insulation Restricting Blue with 3 1.60-3.30 6.4-7.1
47387 2 16 ---
Green Nylon Terminals Blue Stripes [.063-.130] [1/4-9/32]
47386 Red and
1 Spare Wire Cap 328307 Red 22-18 ---
47386-5 Yellow 8.0-8.7
Blue and [5/16-11/32]
47387 2 Spare Wire Cap 328308 Blue 16-14 ---
Green
PIDG FASTON Receptacles
4.8-5.6
48518-2 --- --- 641321-1 (.187 Series) and Yellow■ 26-24 ---
[3/16-7/32]
641324-1 (.110 Series)
68343-1
6.35 3.81-6.35 5.2-6.0
Blue 2 PLASTI-GRIP Terminals Blue 16-14 ---
[.250] [.150-.250] [13/64-15/64]
Exp.

●Use Tight Insulation Support for Wires with Thin Wall Insulation
■For Reference Only – (Check Product-to-Tool Match Using Part Numbers)

Figure 3 (end)

3. Place the product in the jaws as shown in Figure 4 or Figure 5.

4. Close the tool handles until the product is held firmly in place. DO NOT deform the wire barrel.
5. Insert properly stripped wire(s) into the wire barrel as shown in Figure 4 or Figure 5.
CAUTION
DO NOT allow wire insulation to enter the wire barrel.

Figure 4

Rev U 3 of 10
 408-1559

6. Complete the crimp by closing the tool handles until the ratchet releases.
7. Release the tool handles, allow the handles to open fully, and remove the crimped product.
8. To crimp the other wire barrel of a splice, re-position the uncrimped wire barrel in the tool as shown in
Figure 5, and repeat Steps 2 through 7.
9. Inspect the crimped product according to Figure 7. Product not meeting these conditions should NOT
be used. If the wire insulation grip is not satisfactory, refer to Section 4 to adjust the grip using the
insulation crimp adjustment pins.

3.2. Spare Wire Cap

1. Strip the wire to the dimension provided in Figure 3, being careful to avoid nicking or cutting the
conductor(s).
CAUTION
DO NOT use wire with nicked or missing conductor(s).

Figure 5
2. Place the tool insulation crimp adjustment pins in Position 3.
3. Close the tool handles until the jaws partially close, but leave enough space for the spare wire cap to
be inserted between the jaws.
4. Raise the locator so that the end of the cap rests against the recessed surface of the locator as shown
in Figure 6.

Figure 6

Rev U 4 of 10
 408-1559

5. Close the tool handles until the spare wire cap is held firmly in place. DO NOT deform the wire barrel.
6. Insert a properly stripped wire into the wire barrel until the wire bottoms.
7. Hold the wire in position, and complete the crimp by closing the tool handles until the ratchet releases.
8. Release the tool handles, allow the handles to open fully, and remove the crimped spare wire cap.
9. Inspect crimped product according to Figure 7. Product not meeting these conditions should NOT be
used.

Figure 7

Rev U 5 of 10
 408-1559

4. INSULATION CRIMP ADJUSTMENT

The insulation crimp section of the hand tool has three positions: 1 (tight), 2 (medium), and 3 (loose) to adjust
the wire insulation crimp grip. To adjust the insulation grip, proceed as follows:

4.1. PIDG Terminals and Splices and PIDG FASTON Receptacles

NOTE
PIDG terminals and splices feature a wire insulation “grip”.
1. Insert the insulation crimp adjustment pins into Position 3. Refer to Figure 1.
CAUTION
Make sure that both insulation crimp adjustment pins are in the same position.
2. Place a terminal or splice into the tool jaws as shown in Figure 4 or Figure 5.
3. Insert UNSTRIPPED wire into ONLY the insulation barrel of the terminal or splice.
4. Close the tool handles to complete the crimp.
5. Remove the crimped terminal or splice and check the insulation crimp by bending the wire back and
forth once. The terminal or splice should retain its grip on the wire insulation. If the wire pulls out, set
BOTH insulation crimp adjustment pins to the next higher position (2).
6. Perform another crimp, and repeat the adjustment as necessary until the correct insulation grip is
attained. DO NOT use a tighter setting than required.

4.2. PLASTI-GRIP Terminals and Splices

NOTE
PLASTI-GRIP terminals and splices feature a wire insulation “support”. The terminal or splice insulation should ideally be in
contact with the wire insulation.
Set the insulation crimp adjustment pins into position according to the following:
— 3 for wire having a large insulation diameter
— 2 for wire having a medium insulation diameter
— 1 for wire having a small insulation diameter
CAUTION
Make sure that both insulation crimp adjustment pins are in the same position.

5. MAINTENANCE AND INSPECTION

Hand crimping tools are inspected before shipment. The tool received should be inspected immediately upon
arrival to ensure that the tool has not been damaged during shipment, and that it performs according to the
criteria described in this sheet. If a tool is damaged upon arrival, retain the shipping container, file a claim with
the carrier, and notify TE immediately.

5.1. Daily Maintenance

1. Remove dust, moisture, and other contaminants from the tool with a clean brush or a soft, lint-free
cloth. DO NOT use objects that could damage the tool.
2. Make sure that the proper retaining pins are in place and are secured with the proper retaining rings.
3. Make certain that all pins, pivot points, and bearing surfaces are protected with a THIN coat of any
good SAE 20 motor oil. DO NOT oil excessively.
4. When the tool is not in use, keep the handles closed to prevent objects from becoming lodged in the
crimping areas and store the tool in a clean, dry area.

5.2. Periodic Inspection

Regular inspections should be performed by quality control personnel. A record of scheduled inspections
should remain with the tool or be supplied to supervisory personnel responsible for the tool. Though

Rev U 6 of 10
 408-1559

recommendations call for at least one inspection per month, the inspection frequency should be based on the
amount of use, working conditions, operator training and skill, and established company standards. These
inspections should be performed in the following sequence:

Visual Inspection
1. Remove all lubrication and accumulated film by immersing the tool (handles partially closed) in a
suitable commercial degreaser that will not affect paint or plastic material.
2. Make certain that all retaining pins are in place and are secured with retaining rings. If replacements
are necessary, refer to the parts list in Figure 10.
3. Inspect crimping areas for pitted or chipped surfaces.
4. Close the tool handles until the ratchet releases, then allow handles to open freely. If they do not open
quickly and fully, the spring is defective and must be replaced. Refer to Section 6, REPLACEMENT
AND REPAIR.

Gaging Crimping Chamber

This inspection requires the use of plug gages conforming to the dimensions listed in Figure 8. To gage
the crimping chamber, proceed as follows:
1. Close the jaws by squeezing the tool handles together until the jaws have bottomed, and then HOLD
the handles in this position. DO NOT force the jaws beyond initial contact.
2. Align the GO element of the gage with the wire barrel crimp section of the crimping chamber. Refer to
Figure 9. Push the element straight into the crimping chamber without using force. The GO element
must pass completely through the crimping chamber.
3. Align the NO-GO element of the gage with the same crimp section, and try to insert the element. The
NO-GO element may start entry, but it must not pass completely through the crimping chamber. Refer
to Figure 9.
4. Repeat the gage inspection for the insulation crimp section of the crimping chamber, making sure to
use the correct plug gage.
If the crimping chamber conforms to the gage inspection, the tool is considered dimensionally correct. If
the crimping chamber does not conform to the inspection, the tool must be repaired. Refer to Section 6,
REPLACEMENT AND REPAIR.
For additional information concerning the use of the plug gage, refer to Instruction Sheet 408-7424.

Ratchet Inspection
Obtain a .025-mm [.001-in.] shim that is suitable for checking the clearance between the bottoming
surfaces of the jaws. To inspect the ratchet control, proceed as follows:
1. Refer to Figure 3, and select a product and maximum size wire.
2. Position the product in the crimping chamber according to Paragraph 3.1, Steps 1 through 5 or
Paragraph 3.2, Steps 1 through 6.
3. While holding the wire in place, squeeze the tool handles together until the ratchet releases. Holding
the tool in this position, maintain just enough pressure to keep the jaws closed.
4. Check the clearance between the bottoming surfaces of the jaws. If the clearance is .025 mm
[.001 in.] or less, the ratchet is satisfactory. If clearance exceeds .025 mm [.001 in.], the ratchet is out
of adjustment and must be repaired. Refer to Section 6, REPLACEMENT AND REPAIR. If the tool
conforms to this inspection procedure, lubricate it with a THIN coat of any good SAE 20 motor oil, and
return it to service.

6. REPLACEMENT AND REPAIR

Customer-replaceable parts are listed in Figure 10. Parts other than those listed should be replaced by TE to
ensure quality and reliability. For customer repair service or to order replacement parts, call 1-800-522-6752, or
fax your purchase order to 717-986-7605, or write to: Customer Service (038-035), Tyco Electronics
Corporation, PO Box 3608, Harrisburg, PA 17105-3608.

Rev U 7 of 10
 408-1559

7. REVISION SUMMARY
 Updated document to corporate requirements
 Added dimensional callout in Figure 8
 Added new NOTE to Figure 9

JAW CLOSURE♦ DIAMETER A GAGE ELEMENT♦♦ DIAMETER B DIMENSION

TOOL
GO NO-GO GO NO-GO C (WIDTH) R (RADIUS)
46121 1.600-1.608 1.750-1.753
1.600 [.0630] 1.753 [.0690]
169485 [.0630-.0633] [.0689-.0690]
1.600-1.608 1.750-1.753
47304 1.600 [.0630] 1.753 [.0690]
[.0630-.0633] [.0689-.0690]
47386 2.768-2.776 2.918-2.921
2.768 [.1090] 2.921 [.1150]
47386-5 [.1090-.1093] [.1149-.1150]
47387 3.022-3.030 3.172-3.175
3.022 [.1190] 3.175 [.1250] --- ---
68343-1 [.1190-.1193] [.1249-.1250]
2.260-2.268 2.410-2.413
47907-1 2.260 [.0890] 2.413 [.0950]
[.0890-.0893] [.0949-.0950]
1.600-1.608 1.750-1.753
48518-2 1.600 [.0630] 1.753 [.0690]
[.0630-.0633] [.0689-.0690]
2.768-2.776 2.918-2.921
69151-1 2.768 [.1090] 2.921 [.1150]
[.1090-.1093] [.1149-.1150]
2.616-2.624 2.715-2.718
69454 2.616 [.1030] 2.718 [.1070] 3.962 [.156] 3.454 [.136]
[.1030-.1033] [.1069-.1070]

♦Jaw closure dimensions apply when wire barrel jaws are bottomed, but not under pressure. ♦♦Material: Tool Steel

Figure 8 (cont’d)

Rev U 8 of 10
 408-1559

W ±0.13 [±.005]

JAW CLOSURE♦ DIMENSION F GAGE ELEMENT♦♦ DIMENSION G DIMENSION W

TOOL (WIDTH)
GO NO-GO GO NO-GO
46121 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 3.05 [.120]
169485 [.0300-.0303] [.0499-.0500]
47304 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 3.05 [.120]
[.0300-.0303] [.0499-.0500]
47386 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 3.05 [.120]
47386-5 [.0300-.0303] [.0499-.0500]
47387 1.016 [.0400] 1.524 [.0600] 1.016-1.024 1.521-1.524 4.75 [.187]
[.0400-.0403] [.0599-.0600]
47907-1 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 2.36 [.093]
[.0300-.0303] [.0499-.0500]
48518-2 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 3.05 [.120]
[.0300-.0303] [.0499-.0500]
69151-1 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 3.05 [.120]
[.0300-.0303] [.0499-.0500]
69454 0.762 [.0300] 1.27 [.0500] 0.762-0.77 1.267-1.27 3.05 [.120]
[.0300-.0303] [.0499-.0500]
68343-1 1.828 [.0720] 2.337 [.0920] 1.828-1.836 2.334-2.337 4.75 [.187]
[.0720-.0723] [.0919-.0920]

♦Jaw closure dimensions apply when wire barrel jaws are bottomed, but not under pressure. ♦♦Material: Tool Steel

Figure 8 (end)

NOTE: Most insulation barrel gages are designed

to check one side of the crimp nest at a time.
Figure 9

Rev U 9 of 10
 408-1559

PART NUMBER FOR TOOL

ITEM DESCRIPTION 47387 &
46121 47304 47386 47386-5 68343-1
1 RING, Retaining 21045-3 21045-3 21045-3 21045-3 21045-3
2 PIN, Retaining 1-23619-6 1-23619-6 1-23619-6 1-23619-6 1-23619-6
3 PIN, Adjustment 39207 39207 39207 39207 39207
4 SPRING 39364 39364 39364 39364 39364
6 RING, Retaining 21045-6 21045-6 21045-6 21045-6 21045-6
7 PIN, Retaining 2-23620-9 2-23620-9 2-23620-9 2-23620-9 2-23620-9
8 SCREW 3-306105-9 3-21016-4 9-305927-1 9-305927-1 9-305927-1
9 SUPPORT --- 39193 --- --- ---
10 STOP --- 302765 --- --- ---
11 LOCATOR, Housing 302994 --- 302994 302994 302994
12 SPRING 301201 --- 301201 301201 301201
13 LOCATOR 3-304052-6 --- 302993 302993 45965-6

PART NUMBER FOR TOOL

ITEM DESCRIPTION
47907-1 169485 48518-2 69151-1 69454
1 RING, Retaining 21045-3 21045-3 21045-3 21045-3 21045-3
2 PIN, Retaining 1-23619-6 1-23619-6 1-23619-6 1-23619-6 1-23619-6
3 PIN, Adjustment 39207 39207 39207 39207 39207
4 SPRING 39364 39364 39364 39364 39364
6 RING, Retaining 21045-6 21045-6 21045-6 21045-6 21045-6
7 PIN, Retaining 2-23620-9 2-23620-9 2-23620-9 2-23620-9 2-23620-9
8 SCREW 3-306105-9 3-21016-4 9-305927-1 9-305927-1 9-305927-1
9 SUPPORT --- --- --- --- ---
10 STOP --- --- --- --- ---
11 LOCATOR, Housing 302994 302994 302994 302994 302994-1
12 SPRING 301201 301201 301201 301201 2-304668-6
13 LOCATOR 303542 575960-4 125644-7 302993 4-304052-6
Figure 10

Rev U 10 of 10